Installation

Special Tool:

1. Attach the Modular Lifting Bar.
2. Remove the engine from the engine stand.

3. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

If removed, clean and inspect the mating surface.





4. NOTE: If not secured within four minutes, sealant must be removed and sealing area cleaned with Metal Surface Cleaner F4AZ-1913536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

If the retainer plate was removed, apply a 4mm (0.16 in.) bead of silicone around the rear oil sea] retainer sealing surface.
- Use Silicone Gasket and Sealant F4AZ-19562-A or equivalent meeting Ford specification WSE-M4G323-A6.





5. If removed, install the crankshaft rear oil seal retainer and bolts.





6. If removed, install a new crankshaft rear oil seal.
7. If removed, install the crankshaft oil slinger.

Romeo Engine:

Windsor Engine:

8. Install the flywheel and the bolts. Tighten the bolts in the sequence shown.

All Vehicles

9. NOTE: Align the engine-to-transmission dowels before installing engine to transmission bolts.

Position the engine in the vehicle, and remove the Modular Lifting Bar and the jack supporting the transmission.
10. Raise and support the vehicle.





11. Position and install and the LH engine mount.





12. Position and install the RH engine mount.





13. Install and tighten the new nuts.
14. Install the starter motor.





15. Install and tighten the four nuts.





16. NOTE: Only three bolts are required for installation.

Install the bolts.





17. Install the oil cooler to the oil filter adapter, and install the oil bypass filter.





18. On 4x4 vehicles, install the oil cooler.





19. Install the bolts, and install the shifter cable bracket.





20. Install the lower radiator hose.
21. Lower the vehicle.





22. NOTE: Lubricate the O-rings with transmission fluid.

Install the transmission oil filler tube and nut.





23. Install the remaining bolts and the fuel line bracket.





24. Connect the transmission wiring harness and the LH and RH Heated Exhaust Gas Oxygen (HEGO) sensor connectors.





25. On Romeo engines, install the water heater return hose.





26. NOTE: Do not re-use the O-ring seal.

On Windsor engines, slide the water heater tube forward over the new O-ring.
- Lubricate the O-ring seal with Ford Premium Cooling System Fluid E2FZ-19549-AA (in Oregon, F5FZ-19549-CC, in Canada, CXC-8-B) or equivalent meeting Ford specification ESE-M971344-A.

All Vehicles
27. Install the intake manifold.





28. Install the suction line to the accumulator.





29. On 4.6L engines, install the ignition coils and ignition coil mounting brackets.
1 Position LH ignition coil and bracket.
2 Install the nuts.
3 Install the bolt.
4 Position the RH ignition coil and bracket.
5 Install the bolts.





30. On 4.6L engines, connect the following electrical connections:
- RH ignition coil electrical connector (A)
- radio capacitor electrical connector (B)





31. On 4.6L engines, connect the following electrical connections:
- LH ignition coil connector (A)
- Camshaft Position Sensor (CMP) electrical connector (B)
- radio capacitor electrical connector (C)

32. Install the drive belt.
33. Install the A/C condenser.
34. Install the radiator.
35. Install the Engine Air Cleaner (ACL) and the air cleaner outlet tube.





36. Install the power steering reservoir bracket.
37. Fill all fluids to the proper levels.
38. Connect bulkhead connectors.
- Tighten the bolt.

39. Install the hood.
40. Connect the battery ground cable.
41. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
42. Recharge the A/C system.